Anodized inserts for coulomb damping or frictional damping

ABSTRACT

A method comprising providing an insert having a portion capable of being oxidized and electrochemically anodizing the portion capable of being oxidized to provide a layer comprising an oxidized material thereon.

TECHNICAL FIELD

The field to which the disclosure generally relates to includes inserts for use in products requiring damping products including such inserts and methods of making and using the same.

BACKGROUND

A number of products are subject to unwanted vibration during operation. In some cases, such vibration produces unwanted noise.

SUMMARY OF SELECT EXAMPLES OF THE INVENTION

One embodiment includes a method comprising providing an insert, inlay, or cast-in-place piece having a portion thereof capable of being oxidized, and electrochemically anodizing the portion capable of being oxidized to form a layer of oxide material thereon.

BRIEF DESCRIPTION OF THE DRAWINGS

Select examples of embodiments of the invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

FIG. 1 is plan view of an insert for use in a vehicle brake rotor to dampen vibration and sound by frictional movement of the insert with respect to a cast around body portion of the brake rotor cheek, according to one embodiment.

FIG. 2 is a plan view of a sectioned annular insert for use in the brake rotor cheek portion of a vehicle brake rotor to dampen vibration and sound of the brake rotor cheek, according to one embodiment.

FIG. 3 is a plan view of an insert similar to that shown in FIG. 1 but with through holes formed therein.

FIG. 4 is a plan view of a wire mesh annular insert for use in a brake rotor cheek to dampen vibration and sound of the brake rotor cheek, according to one embodiment.

FIG. 5 is a side view of an insert similar to that shown in FIG. 1, according to one embodiment.

FIG. 6 is a side view of an alternative insert similar to FIG. 5 wherein a wave is formed in a portion of the insert, according to one embodiment.

FIG. 7 is a side view of an insert similar to FIG. 5 wherein a portion of the top surface and a portion of the bottom surface have been roughened.

FIG. 8 is a side view of an insert for coulomb or frictional damping having a layer of oxide material thereon deposited by electrochemical anodization.

FIG. 9 is a side view of an insert for coulomb or frictional damping having a portion of the top surface and a portion of the bottom surface having a foil including an oxide of the foil formed thereon by electrochemical anodization.

FIG. 10 is a side view of an insert for coulomb or frictional damping having a foil on its sides and on the top and bottom surfaces including an oxide of the foil formed thereon by electrochemical anodization.

FIG. 11 is a perspective view of an electric drive motor housing having a portion of the housing with an insert for coulomb or frictional damping by frictional movement of the insert with respect to the housing.

FIG. 12 is a side view of a transmission housing having a portion of the housing with an insert for coulomb or frictional damping by frictional movement of the insert with respect to the housing.

FIG. 13 is a side view of a combustion exhaust manifold having a portion of the manifold with an insert for coulomb or frictional damping by frictional movement of the insert with respect to the manifold.

FIG. 14 is a side view of a combustion engine cylinder head having a portion of the cylinder head wall with an insert for coulomb or frictional damping by frictional movement of the insert with respect to the wall of the cylinder head.

FIG. 15 is a perspective view of a differential case having a portion of the case with an insert for coulomb or frictional damping by frictional movement of the insert with respect to the case.

FIG. 16 is a perspective view of an engine block having a portion of the engine block with an insert for coulomb or frictional damping by frictional movement of the insert with respect to the engine block.

FIG. 17 is a perspective view of a rear end housing having a portion of the housing with an insert for coulomb or frictional damping by frictional movement of the insert with respect to the housing.

FIG. 18 is a top view of a golf club having a portion of the head with an insert for coulomb or frictional damping by frictional movement of the insert with respect to the head.

FIG. 19 is a view of a baseball bat having a portion of the bat with an insert for coulomb or frictional damping by frictional movement of the insert with respect to the bat.

FIG. 20 is a side view of an archery bow having stabilizer(s) having a portion of the stabilizer with an insert for coulomb or frictional damping by frictional movement of the insert with respect to the stabilizer.

FIG. 21 is a sectional view of a shaft having an inner portion of the shaft being an insert for coulomb or frictional damping by frictional movement of the insert with respect to the shaft.

FIG. 22 is a sectional view of a shaft having an outer portion of the shaft being a concentric insert for coulomb or frictional damping by frictional movement of the concentric sheath with respect to the shaft.

FIG. 23 is a sectional view of a shaft having a portion of the shaft being an insert located between inner and outer concentric body portions for coulomb or frictional damping by frictional movement of the insert with respect to the inner and outer concentric body portions of the shaft.

FIG. 24 is a sectional view of a hollow shaft having a number of inserts located an equal concentric distance from each other for coulomb or frictional damping by frictional movement of the inserts with respect to the hollow shaft.

FIG. 25 is a sectional view of a hollow shaft having a number of inserts located an equal concentric distance from each other for coulomb or frictional damping by frictional movement of the inserts with respect to the hollow shaft.

FIG. 26 is a perspective view of a vehicle brake rotor having an insert located inside of the brake pad for coulomb or frictional damping by frictional movement of the insert with respect to the brake pad.

Other exemplary embodiments of the invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while disclosing exemplary embodiments of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

DETAILED DESCRIPTION OF SELECT EXAMPLES OF EMBODIMENTS

The following description of the embodiment(s) is merely illustrative in nature and is in no way intended to limit the invention, its application, or uses.

When the term “over,” “overlying,” “overlies,” “under,” “underlying,” or “underlies” is used herein to describe the relative position of a first layer or component with respect to a second layer or component such shall mean the first layer or component is directly on and in direct contact with the second layer or component or that additional layers or components may be interposed between the first layer or component and the second layer or component.

One embodiment of the invention includes a method for making an insert with a layer of oxide formed on a portion thereof including electrochemical anodization of a portion of the insert capable of being oxidized. The term insert as used herein includes any component in which a metal or alloy is cast around a portion thereof including inserts which are completely encased and enclosed by the casting material, partially enclosed by the casting material, or having a portion of the casting material extending there through. An insert may be provided having a body portion. The body portion may include a metal, ceramic, thermoplastic, thermoset, wood, or other simple material for providing a base body portion of an insert for casting a metal or alloy there around and to provide coulomb damping or frictional damping. A metal or alloy is cast around at least a portion of the insert and the portion of the insert with the oxide formed thereon prevents bonding of the cast material thereto. The portion of the insert having the oxide formed thereon also provides a frictional surface for movement against the cast portion to dissipate vibrations of a product containing the insert reducing such vibrations and sound by coulomb damping or frictional damping. In one embodiment, the base body portion of the insert may include any of a variety of oxide-forming metals or alloys, including materials such as Al, Ti, Ta, Si, and Zr. In another embodiment, a layer of oxide forming metal or alloy may be deposited, formed, or secured to at least a portion of the base body of the insert. For example, in one embodiment, the base body portion may be a metal or alloy which does not relatively easily form an oxide, and an oxide-forming metal or alloy may be provided on the base material, for example, but not limited to, electroplating, sputtering, chemical vapor deposition, plasma assisted metal deposition, thermal spray coating, ion implanting, nit riding the surface thereof, or adhering or depositing a metal or alloy foil thereto.

In one embodiment, the layer of oxide may have a thickness ranging from about 100 nm (nanometer) to about 10 μm (micrometers)

In one embodiment, an insert including an aluminum portion is electrochemically anodized in the presence of a solvent that readily provides oxygen upon electrochemical oxidation such as water, methanol, ethanol, glycol, or other alcohols to form an alumina layer comprising aluminum and oxygen. In one embodiment, the layer of alumina is porous. The thickness of the alumina layer, and pore parameters (diameter, length) may be determined largely by the anodization conditions, such as the applied DC voltage, pH of the acid, or time of anodization. For example, in one embodiment, a layer of alumina may be deposited on a portion of an insert capable of being oxidized by anodizing the portion including aluminum for 30 minutes under 60V.

In another embodiment, a portion of an insert including titanium may be anodized in the presence of HF to produce a layer of TiO₂ on the portion of the insert capable of being oxidized. In one embodiment, the layer includes titanium oxide (titania) tubes. In one embodiment, the layer of titanium oxide tubes may be formed by anodizing pure titanium foils secured to a base body portion of the insert. In one embodiment, titanium foils are anodized in 0.5 wt % HF solution.

Another embodiment of the invention may include providing a base body portion of an insert comprising tantalum or a base body portion of the insert having a layer, or foil including tantalum thereon and electrochemically anodizing the tantalum to Ta₂O₅. In one embodiment, the anodation is accomplished in 1M H₂SO₄+2 wt % HF.

Another embodiment of the invention includes a method which may including providing a base body portion of an insert including silicon, or a base body portion of an insert having a layer or foil thereon including silicon and anodizing the silicon in hydrochloric acid solution to form silicon oxide (silica).

Referring now to FIG. 1, one embodiment of the invention may include an insert 10 having an annular portion 12 and one or more tabs 14 which may extend radially outward or inwardly from the annular portion to support the insert in a metal casting mold. In one embodiment, the entire surfaces of the insert may include a metal or alloy which may be electrochemically anodized to provide an oxide surface sufficient in thickness and character such that cast molten metal will not bond thereto. In one embodiment, at least a portion or all of the tabs 14 are not anodized so that cast metal may bond thereto and seal off the annular portion of the insert from the environment in a vehicle brake rotor.

FIG. 2 shows a sectioned annular insert for use in a vehicle brake rotor. The sectioned annular insert may or may not include tabs 14 as shown in FIG. 1.

FIG. 3 shows an insert for use in a vehicle brake rotor similar to the insert of FIG. 1 but with through holes 16 formed therein.

FIG. 4 shows an insert including an annular portion including a wire mesh 18 formed from a plurality of interwoven wires for use in a vehicle brake rotor cheek according to one embodiment.

FIG. 5 is a side view of an insert such as that shown in FIG. 1 illustrating an upper surface 22 and a lower surface 24 which may be substantially flat.

FIG. 6 illustrates an insert similar to FIG. 5 but wherein a wave 26 is provided in a portion of the insert.

FIG. 7 illustrates an insert similar to FIG. 5 but wherein the annular portion 12 has been roughened, for example, by shot-blasting, shot-peening, etching, or the like prior to anodizing the insert.

FIG. 8 illustrates an insert 10 having a base body portion 28 and a layer of oxidized material 30 thereon formed by electrochemical anodation of a metal, alloy or silicon.

FIG. 9 illustrates an insert including a base body portion 28 which may include ceramic, wood, thermoplastic polymer, thermoset polymer, or metal material having foils 32 including a metal or alloy and an oxide of the metal or alloy layer 30 thereon formed by electrochemical anodizing the foils 32. The foils 32 may be formed on the upper surface 22 or the lower surface 24 of the base body portion 28.

FIG. 10 illustrates an insert 10 including a base body portion 28 having a layer of metal on top and bottom surfaces 22, 24, and side surfaces 23, 25 and a metal oxide layer formed on the metal layer 32 by electrochemical anodizing of the metal layer 32.

Referring now to FIG. 11, one embodiment of the invention includes a product which may include an electric drive motor housing including a body portion 506 formed from a cast metal. An insert 504 may be included in the housing as an inlay, or completely enclosed in a wall of the housing. The insert 504 may include tabs 534 as desired. The body portion 506 may be bonded to the tabs 534 as described above.

Referring now to FIG. 12, one embodiment of the invention may include a product 500 which may be a transmission housing including inserts 504 which may be completely enclosed by a wall of the transmission housing or may be provided as an inlay in the wall of the transmission housing according to various embodiments of the invention.

Referring now to FIG. 13, one embodiment of the invention may include a product 500 which may be a combustion exhaust gas manifold including inserts 504 which may be completely enclosed or may be provided as an inlay in a wall forming the combustion engine exhaust gas manifold.

Referring now to FIG. 14, one embodiment of the invention may include a product 500 which may be a combustion engine cylinder head including inserts 504 which may be completely enclosed or provided as an inlay in a wall of the cylinder head.

Referring now to FIG. 15, one embodiment of the invention may include a product 500 which may be a differential case including inserts 504 which may be completely enclosed or provided as an inlay in a wall of the differential case.

Referring now to FIG. 16, one embodiment of the invention may include a product 500 which may be an engine block including inserts 504 which may be completely enclosed or provided as an inlay in a wall of the engine block.

Referring now to FIG. 17, one embodiment of the invention may include a product 500 which may be a rear end housing for a rear wheel drive vehicle including at least one insert 504 which may be completely enclosed or may be provided as an inlay in a wall of the rear end housing.

Referring now to FIG. 18, one embodiment of the invention may include a product 500 which may include a head of a golf club iron which may include an insert 504 therein for providing frictional damping according to one embodiment of the invention. The golf club may include a shaft attached to the head and the insert 504 may be provided in the shaft in addition to or alternatively to providing the insert 504 in the head of the golf club. The insert 504 may provide a frictional damping means to reduce vibration of the head and/or the shaft when the club strikes a golf ball or the ground.

Referring now to FIG. 19, one embodiment of the invention may include a product 500 which may be in the form of a metal baseball bat including an insert 504 as a frictional damping means. The frictional damping means may reduce the vibration of the baseball bat upon striking an object such as a baseball.

Referring now to FIG. 20, one embodiment of the invention may include a stabilizer(s) 600 for an archery bow 602 which may comprise a metal and may include a frictional damping means such as an insert 504 in the body portion 506 of the stabilizer 600 to reduce the vibration of the bow and/or the bow string (not shown) which may occur when shooting an arrow with the bow.

Referring now to FIG. 21, one embodiment of the invention may include a shaft 500 including a frictional damping means which may include an insert 504 as a central core and concentric metal layer as a body portion 506. The insert 504 and the body portion 506 may be keyed to each other so that they rotate together.

Referring now to FIG. 22, one embodiment of the invention may include a shaft 500 having a central metal core as a body portion 506 and a frictional damping means which may include a concentric insert 504 surrounding the body portion 506. The insert 504 and the body portion 506 may be keyed to each other so that they rotate together.

Referring now to FIG. 23, one embodiment of the invention may include a bearing 500 including a frictional damping means which may include a cylindrical insert 504 surrounded by an inner and outer concentric body portion 506 which may be made of a metal. The bearing 500 may have a bore 604 extending there through to receive a shaft therein. A shaft rotating in the bearing 500 may have a destructive resonance frequency which could result in damage to the part in which the bearing 500 is located. The insert 504 provides a frictional damping means to dissipate undesirable vibration or osculation of the shaft.

Referring now to FIG. 24, another embodiment of the invention may include a bearing 500 including a frictional damping means which may include three lobe inserts 504 which may be positioned at 60 degrees With respect to each other or at an equal distance from each other. The inserts 504 may serve to reduce the vibration or osculation of a shaft spinning in the bore 604 of the bearing. Similarly, as illustrated in FIG. 25, another embodiment may include a bearing 500 having five lobe inserts 504 equally spaced from each other.

Referring now to FIG. 26, one embodiment of the invention may include a vehicle brake rotor 500 which may include a body portion 506 which may be a brake'rotor cheek 606 having a first flat face 608 and an opposite flat face 610 for engagement with a brake pad. The brake rotor includes a frictional damping means which may include an insert 504 received in the brake cheek 606. The vehicle brake rotor 500 may include a hub portion 612 attached to the cheek 606. The hub portion 612 may include a central aperture 614 and a plurality of bolt holes 616 for attaching the brake rotor to a vehicle drive system.

Another embodiment of the invention includes a machine such as a stamping machine, band saw, drill or the like which includes a wall comprising a metal which is vibrated during operation of the machine, and wherein the wall includes a friction damping means including but not limited to an insert, as described above. 

What is claimed is:
 1. A method comprising; providing an insert having a portion capable of being oxidized and electrochemically anodizing the portion capable of being oxidized to provide a layer comprising an oxidized material thereon.
 2. The method of claim 1 wherein the layer may have a thickness ranging from about 100 nanometers to about 10 microns.
 3. The method of claim 1 wherein the layer is porous.
 4. The method of claim 1 wherein the insert comprises aluminum and is electrochemically anodized in the presence of water to form a layer of Al₂O₃.
 5. The method of claim 1 wherein the insert comprises silicon and is electrochemically anodized in the presence of a hydrochloric acid solution.
 6. The method of claim 1 wherein the insert comprises titanium and is electrochemically anodized in the presence of HF to form a layer of TiO₂.
 7. The method of claim 6 wherein the layer comprises titanium oxide tubes.
 8. The method of claim 1 wherein the oxide forming material comprises tantalum.
 9. A method comprising; providing an insert comprising a base body portion comprising a metal or silicon, and electrochemical anodizing the metal or silicon to provide a layer of oxide, on the base body portion, and casting a product with the insert as a portion thereof comprising flowing molten metal against the layer of oxide and wherein the thickness and properties of the layer of oxide are such that the molten metal does not bond to the layer of oxide and cooling the molten metal to provide a product having the insert received to provide coulomb damping of the product.
 10. The method of claim 9 wherein the insert comprises aluminum and is electrochemically anodized in the presence of a solvent to form a layer of alumina comprising aluminum and oxygen.
 11. The method of claim 9 wherein the layer is porous.
 12. The method of claim 9 wherein the insert comprises silicon and is electrochemically anodized in the presence of a hydrochloric acid solution.
 13. The method of claim 9 wherein the insert comprises titanium and is electrochemically anodized in the presence of HF to form a layer of titania.
 14. The method of claim 13 wherein the layer comprises titanium oxide tubes.
 15. A method comprising; providing an insert having a portion not easily capable of forming an oxide; providing an oxide forming material on the portion not easily capable of forming an oxide by electroplating, sputtering, chemical vapor deposition, plasma assisted metal deposition, thermal spray coating, ion implanting, nitriding the surface thereof, or adhering or depositing a metal or alloy foil thereto or the like; and electrochemical anodizing the portion capable of oxidizing to provide a layer comprising an oxidized material thereon.
 16. The method of claim 15 wherein the oxide forming material comprises aluminum and is electrochemically anodized in the presence of water to form a layer of alumina comprising alumina and oxygen.
 17. The method of claim 15 wherein the oxide forming material comprises silicon and is electrochemically anodized in the presence of a hydrochloric acid solution.
 18. The method of claim 15 wherein the layer is porous.
 19. The method of claim 15 wherein the oxide forming material comprises titanium and is electrochemically anodized in the presence of HF to form a layer of titania.
 20. The method of claim 19 wherein the layer comprises titanium oxide tubes.
 21. The method of claim 15 where the oxide forming material comprises tantalum.
 22. The method of claim 21 wherein the oxide forming material is electrochemically anodized in 1M H₂SO₄+2 wt % HF.
 23. The method of claim 9 wherein the product is an automobile component.
 24. The method of claim 9 wherein the insert is constructed and arrange to physically support itself inside of a metal casting mold. 